XL1000 Load Bank
Read all instructions before using the load bank Contents Contents... 2 1) Receiving... 4 a. Load Bank... 4 b. Manual... 4 2) Specifications... 5 a. Mechanical... 5 i. Lifting... 5 ii. Enclosure... 5 iii. Cooling... 5 b. Electrical... 5 i. Control power... 5 ii. Load power... 5 iii. Cooling... 6 3) Installation (Optional)... 7 a. Customer Connections... 7 4) Safety... 8 a. Grounding... 8 b. Power Connection... 8 c. Intake and Exhaust Ports... 8 d. Misuse of Product... 8 e. Common Best Practices... 9 5) Operation... 10 a. Pre-Start Up... 10 b. Auto Load Dump... 10 i. Using the auto load dump feature... 10 ii. Bypassing the auto load dump feature... 10 c. Start Up... 10 i. Using internal control and fan power... 10 ii. Using external control and fan power... 11 d. Applying and Disconnecting Load... 11 e. Acuvim II Power Quality Meter... 12 f. Shut Down... 12 6) Troubleshooting... 13 a. Load bank will not turn on... 13 b. Blower will not turn on... 13 c. Load steps will not turn on... 13 d. Over temperature fault... 13 7) Maintenance... 14 a. Replacing a fuse... 14 i. Main Control (FC) and Main Meter (FM) Fuses... 14 ii. Meter (FMA, FMB, FMC) Fuses... 14 iii. Main Power Fuses... 15 iv. Control (FVSA, FVSB, FVSC) Fuses... 15 2
v. Blower (FBA, FBB, FBC) Fuses... 15 b. Replacing Contactors... 16 c. Replacing Resistors... 16 d. Preventative Maintenance... 16 8) Service Parts... 17 9) Copyright... 18 3
1) Receiving Check the unit for obvious damage and report any exterior damage to the carrier immediately. a. Load Bank 1x b. Manual 1x XL1000 Owner s Manual 4
2) Specifications a. Mechanical i. Lifting The XL1000 Load bank is equipped with fork tubes for lifting. DO NOT lift the unit by any other means; this could cause severe damage. Fork Channels ii. Enclosure iii. Cooling 1. Electro-statically applied powder coat, Blue: PPG PCUP70103. 2. Air inlet and exhaust are covered by metal screens. 3. Heat is discharged horizontality. The XL1000 unit is equipped with one 36 inch panel fan providing 14,400 CFM. The unit is equipped with air flow sensors to ensure adequate cooling air is getting to the resistors. b. Electrical i. Control power Each unit is equipped with a step down transformer to convert the load power to 120VAC single phase 60 Hz. The unit is also equipped with auxiliary terminal blocks in cases where the control and fan power cannot be sourced internally from the load power. ii. Load power 1. The XL1000 is designed to accept 0-528VAC 3-Phase, 3-Wire 60 Hz load power with external control power (190-264 / 415-528VAC 3-Phase 60 Hz when control and fan power are sourced internally) 5
Resolution (kw) Capacity (kw) Current at Capacity (Amps) 480VAC 240VAC 208VAC 480VAC 240VAC 208VAC 480VAC 240VAC 208VAC 5 5 3.75 1000 1000 750 1202.81 2405.63 2081.79 iii. Cooling 2. The kw output at each step is subject to a manufacturing tolerance of ±5%. 3. The unit is designed for continuous duty at 1.0 power factor. 1. The blowers equipped in the unit are powered either directly off of the load power or off of the auxiliary plug. The acceptable voltage range for the fan is: 415-528VAC 3-Phase 60 Hz for the single voltage models and 190-264 / 415-528VAC 3-Phase 60 Hz for the dual voltage models. 2. The power associated with the fan is 15HP maximum. 6
3) Installation (Optional) a. Customer Connections i. To connect External Power, remove the four #10 truss screws. ii. Feed the wires through the strain relief valve. iii. Connect wires to the terminal blocks. iv. Close and secure Connection Panel. #10 Truss Screws Strain Relief Terminal Blocks (Top Down) ALDL Auto Load Dump, Line ALDG Auto Load Dump, Ground ALDN Auto Load Dump, Neutral EXA External Control / Fan Power, A Phase EXB External Control / Fan Power, B Phase EXC External Control / Fan Power, C Phase EXG External Control / Fan Power, Ground Back View of Connection Panel 7
4) Safety a. Grounding The load bank must be firmly and electrically connected to earth ground via the grounding cams or the grounding stud found on the unit. Failure to do so could allow deadly voltage to be present on the surface of the enclosure. The grounding connection provides a low resistance path to ground. This grounding protects the operator from the possibility of electrical shock. b. Power Connection All power connection must be connected or guarded. Failure to do so will expose the operators to shock, causing severe damage or death. Without properly guarded connections, the unit is in danger of grounding-out or shorting-out the test power source. c. Intake and Exhaust Ports The unit must have free-flowing air through the intake and exhaust ports to provide adequate cooling to the resistive elements. The resistive elements convert electrical energy into heat. If the unit does not have a free flowing intake and exhaust port, the heat will build up inside of the unit and cause mechanical failure, leading to an electrical short circuit, ultimately damaging the unit and test power source. To increase the life of the resistive elements, allow the fans to run at least three minutes after the load is removed. No ductwork is permitted on the intake or exhaust of this unit as it will cause backpressure and limit the cooling of the resistive elements. Keep exhaust port clear for 20 ft. to allow full free-flowing. d. Misuse of Product DO NOT exceed the recommended load limit of the test power source equipment manufacturer. Damage of the test power source equipment will occur if overpowered. 8
e. Common Best Practices i. Read all instructions before using this load bank. ii. This load bank is hot when in use. To avoid burns, do not let bare skin touch hot surfaces. Keep combustible materials at least 6 feet (1.8 meters) from the front of the load bank and keep them away from the sides and rear. iii. Do not operate any load bank with a damaged cord or plug or after the load bank malfunctions or has been dropped or damaged in any manner. Discard load bank or return to authorized service facility for examination and/or repair. iv. Always unplug load bank when not in use. v. Do not run cord under carpeting. Do not cover cord with throw rugs, runners, or similar coverings. vi. Arrange cord away from traffic areas and where it will not be tripped over. vii. Connect to properly grounded outlets only. viii. Do not insert or allow foreign objects to enter any ventilation or exhaust opening as this may cause an electric shock or fire, or damage the heater/load bank. ix. To prevent a possible fire, do not block air intakes or exhaust in any manner. x. Do not use it in areas where gasoline, paint, or flammable liquids are used or stored. xi. Use this load bank only as described in this manual. Any other use not recommended by the manufacturer may cause fire, electric shock, or injury to persons. xii. Always plug load banks directly into a wall outlet/receptacle. Never use with a re-locatable power tap (outlet/power strip). xiii. This load bank includes a visual alarm to warn that parts of the load bank are getting excessively hot. If the alarm light goes on, immediately turn the load bank off and inspect for any objects on or adjacent to the load bank that may cause high temperatures. DO NOT OPERATE THE LOADBANK WITH THE ALARM LIGHT ON. xiv. SAVE THESE INSTRUCTIONS. 9
5) Operation Please contact Mosebach Manufacturing if you are planning on operating the load bank in ambient temperatures above 46 ºC. Ambient plus heat generated by the resistive elements can cause electrical components to possibly malfunction. a. Pre-Start Up i. Check housekeeping in the operational area and correct all unsafe conditions. ii. Failure to do this may result in debris being blown around and may cause a fire hazard. iii. Check the switch panel and move all switches to the OFF position. iv. Position the load bank so that air will flow freely into the intake and out of the exhaust port. v. All air intakes and exhaust ports must be clear. b. Auto Load Dump i. Using the auto load dump feature 1. Connect grid power to the 3 external terminal blocks located on the Cam Lock connection panel as shown in Section 3-a Customer Connections (ALDL Line, ALDN Neutral, ALDG Ground). 2. Turn the Load Dump switch to On. 3. If the grid power fails, the load bank will shut down and drop all electrical load from the test power source. ii. Bypassing the auto load dump feature 1. To bypass the auto load dump feature, simply place the Load Dump switch to Bypass ; this will now bypass the load dump feature and allow the load bank to operate without any grid power being applied to the 3 external terminal blocks. c. Start Up i. Using internal control and fan power 1. Connect the ground Cam Locks or ground stud on the unit directly to a known earth-ground. 2. Connect all de-energized load power Cam Locks to the unit. 3. Set the Blower/Control Switch to the correct position. 4. Energize the load power source with an acceptable voltage. 5. Turn the MAIN on/off power switch to the ON position. The unit will only run if an acceptable voltage is supplied. 10
ii. Using external control and fan power 1. Connect the ground Cam Locks or ground stud on the unit directly to a known earth-ground. 2. Connect all de-energized load power Cam Locks to the unit. 3. Connect the external power source cables to the external terminal blocks located on the Cam Lock connection panel as shown in Section 3-a Customer Connections (EXA A phase, EXB B phase, EXC C phase, EXG - Ground). 4. Set the Blower/Control Switch to the correct position. 5. Energize the external power source with an acceptable voltage. 6. Energize the load power source with an acceptable voltage 7. Turn the MAIN on/off power switch to the ON position. The unit will only run if an acceptable voltage is supplied. d. Applying and Disconnecting Load i. Start with the Main Power switch located in the ON position, the Blower/Control Source switch in the correct position, and the Master switch in the OFF position. ii. Turn the Blower switch to the ON position. Load can only be applied if the blower is on and the unit is getting adequate airflow. iii. iv. Shock Loading 1. Begin with the Master switch in the OFF position 2. Place the desired test step switches in the ON position. 3. Place the Master switch ON to engage all selected load simultaneously. Step Loading 1. Begin with the Master switch in the ON position. 2. Place desired step switches in the ON position to apply load step by step. v. Disconnect individual steps by placing the step switches in the OFF position and/or disconnect all load simultaneously by placing the Master switch in the OFF position. vi. Step and Shock loading can be used in conjunction with one another during testing. vii. Repeat tests as needed. 11
e. Acuvim II Power Quality Meter i. Press the VA button on the front of the meter to view and cycle through the line voltage and current options. ii. Press the P button on the front of the meter to view and cycle through the Power Reading and Power Factor options. iii. You will find more detailed instructions on the use of your meter by visiting https://accuenergy.com/ and creating an Accuenergy account. f. Shut Down i. Ensure the Master switch and all step switches are in the OFF position. ii. Allow blower(s) to operate for at least three minutes (or until exhaust air is cool) before shutting them off. This cooling period will extend the life of your load bank. iii. Turn the Main Power Switch to the OFF Position. iv. De-energize the external power source (if applicable) and the load power source. v. Remove the de-energized external power source cables from the external terminal blocks (if applicable). vi. Remove the de-energized load power Cam Locks from the unit (if applicable). vii. Remove the ground Cam Locks from the unit (if applicable). viii. Remove Ethernet/Data connections (if applicable). ix. Close and secure all doors to protect delicate hardware. 12
6) Troubleshooting a. Load bank will not turn on i. Make sure the Main Power switch is in the ON position. ii. Make sure the Blower/Control Source cam switch is in the correct position. iii. Check if the auto load dump grid power is energized or the auto load dump switch is in the bypass position. iv. Check the control fuses. b. Blower will not turn on i. Make sure the load bank is turning on. ii. Make sure the Blower/Control Source cam switch is in the correct position. iii. Check for debris preventing the fan(s) from turning. iv. Check the blower fuses. c. Load steps will not turn on i. Make sure the load bank is turning on. ii. Make sure the test power source is energized. iii. Make sure the blower is on. iv. Make sure the Master switch is in the ON position. v. Check if the over temperature red light is on. vi. Check the main power fuses. vii. Check for resistor continuity. viii. Ensure the airflow is suitable and the pressure sensor is not malfunctioning. d. Over temperature fault i. Turn off the unit and disable the source power immediately. ii. This is an indication that the internal cabinet temperature has exceeded 150 ºF. iii. Make sure the cabinet is ventilated. iv. Make sure the temperature sensor is operating. The temperature sensor should be normally closed below 150 ºF. 13
7) Maintenance All maintenance should be conducted on a de-energized unit. Operator is to confirm prior to performing any maintenance. a. Replacing a fuse i. Main Control (FC) and Main Meter (FM) Fuses These fuses are located on the front of the switch and may be removed by pushing down and twisting the front of the fuse cover. For units with the outdoor kit, use a flat head screw driver to twist the quarter-turn cams 90º to disengage each. Once the quarter-turn cams are disengaged, use the black handles to lift the access panel to access the switch panel. Meter Fuse ii. Meter (FMA, FMB, FMC) Fuses Control Fuse These fuses are located on the inside of the switch panel door. They may be accessed by using a flat head screw driver to turn the 3 quarterturn cams 90º to disengage each. The door may then be opened and the fuses can be found on the din rail located on the back of the door. To remove a fuse from the holder, pry the fuse out of the spring locked fuse holder. Meter Fuses 14
iii. Main Power Fuses The main power fuses are located on a series of bus bars behind a cover panel located directly above the Cam Lock panel. To open this panel, remove the 13 Hex Head screws located around the outside of this cover panel. Blower Fuses Main Power Fuses Control Fuses To remove any of the main fuses, remove the respective bolts holding the fuse to the bus bar and cable(s). Be sure to not lose any hardware as it can be detrimental to the unit if left inside during operation. iv. Control (FVSA, FVSB, FVSC) Fuses The control fuses are located behind a cover panel located directly above the Cam Lock panel. To open this panel, remove the 13 Hex Head screws located around the outside of this cover panel. The control fuses are located on a din rail to the left of the bus bar inside of the unit. To remove a fuse from the holder, pry the fuse out of the spring locked fuse holder. v. Blower (FBA, FBB, FBC) Fuses The blower fuses are located behind a cover panel located directly above the Cam Lock panel. To open this panel, remove the 13 Hex Head screws located around the outside of this cover panel. The blower fuses are located on a din rail to the left side inside behind cover. To remove a fuse from the holder, pry the fuse out of the spring locked fuse holder. 15
b. Replacing Contactors Contact Mosebach Manufacturing Co. if there is a contactor that needs to be replaced. c. Replacing Resistors Contact Mosebach Manufacturing Co. if there is a problem with the resistors or if a resistor needs to be replaced. d. Preventative Maintenance Do not use a power washer to clean off the exterior of the unit. It is high voltage electrical equipment. Action Walk around the unit and inspect for: Frequency Every use a) Obvious damage b) Loose hardware Cold Resistance Check Air Flow Test Power Test Open Control Panel and Inspect for: Every 6 months Every 6 months Every 6 months Every 6 months a) Loose wire connections b) Visually damaged components Inspect Fan Inspect Resistors for: Annually Annually a) Damage to coils b) Delamination of the mica Contactors are opening and closing Annually 16
8) Service Parts Common Parts Part Number Blower Blower Motor Meter Green Illuminated Switch Black Switch Green Light Red Light Pressure Switch OTS Sensor BLWR-0055-0132 BLWR-0055-0133 EC-9500-1460 EC-9500-1906 EC-9500-2145 EC-9500-1903 EC-9500-1904 EC-9500-1970 SWIT-003 Part Number Resistor Elements Fuses Cam Switch RA-0055-0378-01 RA-0055-0378-02 RA-0055-0378-03 RA-0055-0378-04 RA-0055-0378-05 RA-0055-0378-06 RA-0055-0378-07 RA-0055-0378-08 RA-0055-0378-17 RA-0055-0378-18 1A Type AGC = EC-9500-1848 10A Type AGC = EC-9500-1577 1A = EC-9500-0247 10A = EC-9500-0244 90A = EC-9500-1670 350A = EC-9500-1169 700A = EC-9500-1915 900A = EC-9500-1048 EC-9500-2171 17
9) Copyright Copyright 2017 Mosebach Manufacturing Company MOSEBACH MANUFACTURING COMPANY 1417 McLaughlin Run Road Pittsburgh, PA 15241-3103 USA T: 412.220.0237 Customer Care F: 412-220-0236 www.mosebachresistors.com OM-XL1000.doc Nov 22, 2017 SAVE THESE INSTRUCTIONS 18